U.S. patent number 6,645,414 [Application Number 09/975,177] was granted by the patent office on 2003-11-11 for method for making multi-layered cores for golf balls.
This patent grant is currently assigned to Acushnet Company. Invention is credited to Daniel Ditzel, Steven Earle, John W. Kennedy, Thomas E. Moore, Walter L. Reid, Jr., Stephen K. Scolamiero.
United States Patent |
6,645,414 |
Reid, Jr. , et al. |
November 11, 2003 |
Method for making multi-layered cores for golf balls
Abstract
A method of making a golf ball core, including the steps of
providing a plurality of centers; providing a top mold plate
defining a first plurality of cavities, a bottom mold plate
defining a second plurality of cavities corresponding to the first
cavities, and a center mold plate disposed between the top and
bottom mold plates and comprising a plurality of corresponding
protrusions; forming a plurality of shells from a layer material by
placing the layer material into the top and bottom mold plate
cavities; and molding the layer material around the protrusions of
the center plate by applying at least one of heat and pressure to
the top and bottom mold plates such that the layer material has a
different temperature than the mold plates; opening at least one
mold plate from the center plate and placing the centers in the
shells; and joining the top and bottom mold plates to join the
shells around the centers.
Inventors: |
Reid, Jr.; Walter L.
(Mattapoisett, MA), Scolamiero; Stephen K. (Bristol, RI),
Moore; Thomas E. (Cohasset, MA), Kennedy; John W.
(Cohasset, MA), Earle; Steven (Plympton, MA), Ditzel;
Daniel (Hanover, MA) |
Assignee: |
Acushnet Company (Fairhaven,
MA)
|
Family
ID: |
23480672 |
Appl.
No.: |
09/975,177 |
Filed: |
October 11, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
375382 |
Aug 17, 1999 |
6303065 |
|
|
|
Current U.S.
Class: |
264/248; 264/255;
264/279.1; 264/297.5; 264/297.8 |
Current CPC
Class: |
B29C
43/04 (20130101); B29C 43/18 (20130101); B29C
69/004 (20130101); B29L 2009/00 (20130101); B29L
2031/545 (20130101) |
Current International
Class: |
B29C
43/04 (20060101); B29C 43/18 (20060101); B29C
69/00 (20060101); B29C 043/00 (); B29C
065/02 () |
Field of
Search: |
;264/255,254,248,279.1,297.5,297.7,297.8 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Lee; Edmund H.
Attorney, Agent or Firm: Lacy; William B.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No.
09/375,382, filed Aug. 17, 1999, now U.S. Pat. No. 6,303,065, which
is incorporated herein, in its entirety, by express reference
thereto.
Claims
What is claimed:
1. A method of making a golfball core, comprising the steps of:
providing a plurality of centers; providing a top mold plate
defining a first plurality of cavities, a bottom mold plate
defining a second plurality of cavities corresponding to the first
cavities, and a center mold plate disposed between the top and
bottom mold plates and comprising a plurality of corresponding
protrusions, forming a plurality of shells from a layer material
by: i) placing the layer material into the top and bottom mold
plate cavities; and ii) molding the layer material around the
protrusions of the center plate by applying heat and pressure to
the top and bottom mold plates such that the layer material has a
different temperature than the mold plates; opening at least one of
the top or bottom mold plates from the center plate and placing the
centers in the shells; and joining the top and bottom mold plates
to join the shells around the centers.
2. The method of claim 1, wherein the step of forming a plurality
of shells further comprises the step of locating the top mold plate
between the center and bottom mold plates so that the cavities in
the top mold plate are adjacent to the center mold plate and the
top, center and bottom mold plates are vertically aligned.
3. The method of claim 2, wherein the step of locating the top mold
plate further includes vertically moving the center mold plate from
an elevated position to a rotate position.
4. The method of claim 3, wherein the step of locating the top mold
plate further includes vertically moving the top mold plate from a
lower position to the rotate position.
5. The method of claim 4, further including after the step of
applying heat and pressure to the top and bottom mold plates,
vertically moving the center mold plate from the rotate position to
the elevated position, and vertically moving the top mold plate
from the rotate position to the lower position.
6. The method of claim 2, wherein the step of locating the trip
mold plate further includes horizontally moving the center mold
plate from a first position substantially vertically unaligned with
the top mold plate to a second position substantially vertically
aligned with the top mold plate.
7. The method of claim 2, wherein the step of forming a plurality
of core hemispherical shells from elastomeric material further
includes: providing a lower elevator having a movable upper plate;
and after applying heat and pressure to the top and bottom mold
plates, separating the mold plates by moving the upper plate
upward.
8. The method of claim 1, wherein the step of forming a plurality
of shells comprises placing elastomeric material into the top and
bottom mold plate cavities.
Description
FIELD OF THE INVENTION
The present invention is directed to a method and apparatus for
making golf balls. More particularly, the invention is directed to
a method and apparatus for forming multi-layered cores or golf
balls that are substantially automated.
BACKGROUND OF THE INVENTION
Generally, golf balls have been classified as solid balls or wound
balls. Solid balls are generally comprised of a solid polymeric
core and a cover. These balls are generally easy to manufacture,
but are regarded as having limited playing characteristics. Wound
balls are comprised of a solid or liquid-filled center surrounded
by tensioned elastomeric material and a cover. Wound balls
generally have good playing characteristics, but are more difficult
to manufacture than solid balls.
The prior art is comprised of various golf balls that have been
designed to provide optimal playing characteristics. These
characteristics are generally the initial velocity and spin of the
golf ball, which can be optimized for various players. For
instance, certain players prefer to play a ball that has a high
spin rate for playability. Other players prefer to play a ball that
has a low spin rate to maximize distance. However, these balls tend
to be hard feeling and difficult to control around the greens.
Manufacturers have molded layers around a solid center by placing a
preformed center between two blocks of core material in a spherical
compression mold, and closing the mold. This process, however,
provides little control over the ultimate placement of the center
within the golf ball core. Large variations in the location of the
center can result.
The prior art also provides for the manufacture of double cover
golf balls. This is generally accomplished by injection molding a
first and then a second cover layer around a core. This system,
however, requires complex injection molds, usually with retractable
pins within the mold to properly position the core. Moreover, this
system generally works better with thermoplastic materials.
Therefore, what is desired is a method and apparatus for molding
multi-layer cores or multi-layer covers that ensures properly
centered balls.
SUMMARY OF THE INVENTION
The present invention is directed to a method of making a golf ball
core, comprising the steps of providing a plurality of centers;
providing a top mold plate defining a first plurality of cavities,
a bottom mold plate defining a second plurality of cavities
corresponding to the first cavities, and a center mold plate
disposed between the top and bottom mold plates and comprising a
plurality of corresponding protrusions; forming a plurality of
shells from a layer material by placing the layer material into the
top and bottom mold plate cavities; and molding the layer material
around the protrusions of the center plate by applying at least one
of heat and pressure to the top and bottom mold plates such that
the layer material has a different temperature than the mold
plates; opening at least one mold plate from the center plate and
placing the centers in the shells; and joining the top and bottom
mold plates to join the shells around the centers.
Additionally, the step of forming a plurality of shells may further
include the step of locating the top mold plate between the center
and bottom mold plates so that the cavities in the top mold plate
are adjacent to the center mold plate and the top, center and
bottom mold plates are vertically aligned.
In one embodiment, the step of locating the top mold plate further
includes vertically moving the center mold plate from an elevated
position to a rotate position. The step of locating the top mold
plate may further include vertically moving the top mold plate from
a lower position to the rotate position. Following the step of
applying heat and pressure to the top and bottom mold plates, the
center mold plate may be vertically moved from the rotate position
to the elevated position, and vertically moving the top mold plate
from the rotate position to the lower position.
In another embodiment, the step of locating the top mold plate
further includes horizontally moving the center mold plate from a
first position substantially vertically unaligned with the top mold
plate to a second position substantially vertically aligned with
the top mold plate. Additionally, the step of forming a plurality
of core hemispherical shells from elastomeric material further
includes providing a lower elevator having a movable upper plate;
and after applying heat and pressure to the top and bottom mold
plates, separating the mold plates by moving the upper plate
upward. The step of forming a plurality of shells may preferably
include placing elastomeric material into the top and bottom mold
plate cavities.
The present invention is also directed to a golf ball comprising a
center and at least one cover layer, formed from the steps of
providing a plurality of centers; providing a top mold plate
defining a first plurality of cavities, a bottom mold plate
defining a second plurality of cavities corresponding to the first
cavities, and a center mold plate disposed between the top and
bottom mold plates and comprising a plurality of corresponding
protrusions; forming a plurality of shells from a layer material by
placing the layer material into the top and bottom mold plate
cavities; and molding the layer material around the protrusions of
the center plate by applying at least one of heat and pressure to
the top and bottom mold plates such that the layer material has a
different temperature than the mold plates; opening at least one
mold plate from the center plate and placing the centers in the
shells; and joining the top and bottom mold plates to join the
shells around the centers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a liquid-filled ball formed
using the method and apparatus of the present invention;
FIG. 2 is a cross-sectional view of a solid ball formed using the
method and apparatus of the present invention;
FIG. 3 is a perspective view of a molding apparatus according to
the present invention;
FIG. 4 is an enlarged, side view of a lower elevator assembly prior
to engaging a bottom mold plate;
FIG. 5 is a perspective view of a frame assembly of the apparatus
of FIG. 3;
FIG. 6 is an enlarged, perspective view of a guide assembly on the
frame assembly of FIG. 5;
FIG. 7 is an enlarged, perspective view of a slide assembly of the
apparatus;
FIG. 8 is an enlarged, perspective view of the lower elevator
assembly of the apparatus of FIG. 3;
FIG. 9 is an enlarged, perspective view of an upper elevator
assembly of the apparatus of FIG. 3;
FIG. 10 is a partial enlarged, perspective view of a portion of the
frame assembly shown in FIG. 3;
FIG. 10A is an enlarged, partial, cross-sectional view of a
rotating assembly taken along arrow 10A--10A of FIG. 10;
FIG. 11 is an enlarged, partial, top view of the rotating assembly
of FIG. 10A with a top mold plate retained therein;
FIG. 12 is an exploded, enlarged, perspective view of a lock
assembly of the apparatus of FIG. 3;
FIG. 13 is an enlarged, perspective view of a mold press of the
apparatus of FIG. 3, wherein portions are broken away for
clarity;
FIG. 14 is an enlarged, top view of the bottom mold plate shown in
FIG. 4;
FIG. 15 is an enlarged, top view of the top mold plate shown in
FIG. 4;
FIG. 16 is an enlarged, top view of a center mold plate shown in
FIG. 4; and
FIGS. 17 and 18 are schematic perspective views illustrating
step-by-step the method of forming a two-layer core according to
the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, ball 2 includes a cover 4 surrounding a core
5. The core 5 has a center or inner core 6 that is disposed
concentrically within the cover and is a fluid center 7 in a cavity
within an inner layer 8. The core 5 also has an outer core 9, which
surrounds the center 6.
Referring to FIG. 2, ball 2' includes a cover 4 surrounding a core
5. The core 5 has a center or inner core 6' that is disposed
concentrically within the cover, and which comprises a solid
sphere, as set forth below. The core 5 also has an outer core 9,
which surrounds the center 6'.
The cover 4 provides the interface between the ball 2 or 2' and a
club and other objects such as trees, cart paths, and grass.
Properties that are desirable for the cover are good moldability,
high abrasion resistance, high tear strength, high resilience, and
good mold release, among others.
The cover 4 can be comprised of polymeric materials such as ionic
copolymers of ethylene and an unsaturated monocarboxylic acid,
which are available under the trademark SURLYN.RTM. of E.I. DuPont
De Nemours & Company of Wilmington, Del. or IOTEK.RTM. or
ESCOR.RTM. from Exxon. These are copolymers or terpolymers of
ethylene and methacrylic acid or acrylic acid partially neutralized
with zinc, sodium, lithium, magnesium, potassium, calcium,
manganese, nickel or the like.
In accordance with the preferred balls, the cover 4 has a thickness
to generally provide sufficient strength, good performance
characteristics and durability. Preferably, the cover 4 is of a
thickness from about 0.03 inches to about 0.12 inches. More
preferably, the cover 4 is about 0.04 to 0.09 inches in thickness
and, most preferably, is about 0.05 to 0.085 inches in
thickness.
In one preferred embodiment, the cover 4 can be formed from
mixtures or blends of zinc, lithium and/or sodium ionic copolymers
or terpolymers.
The Surlyn.RTM. resins for use in the cover 4 are ionic copolymers
or terpolymers in which sodium, lithium or zinc salts are the
reaction product of an olefin having from 2 to 8 carbon atoms and
an unsaturated monocarboxylic acid having 3 to 8 carbon atoms. The
carboxylic acid groups of the copolymer may be totally or partially
neutralized and might include methacrylic, crotonic, maleic,
fumaric or itaconic acid.
This invention can likewise be used in conjunction with
homopolymeric and copolymer materials such as:
(1) vinyl resins such as those formed by the polymerization of
vinyl chloride, or by the copolymerization of vinyl chloride with
vinyl acetate, acrylic esters or vinylidene chloride.
(2) Polyolefins such as polyethylene, polypropylene, polybutylene
and copolymers such as ethylene methylacrylate, ethylene
ethylacrylate, ethylene vinyl acetate, ethylene methacrylic or
ethylene acrylic acid or propylene acrylic acid and copolymers and
homopolymers produced using single-site catalyst.
(3) Polyurethanes such as those prepared from polyols and
diisocyanates or polyisocyanates and those disclosed in U.S. Pat.
No. 5,334,673.
(4) Polyureas such as those disclosed in U.S. Pat. No.
5,484,870.
(5) Polyamides such as poly(hexamethylene adipamide) and others
prepared from diamines and dibasic acids, as well as those from
amino acids such as poly (caprolactam), and blends of polyamides
with Surlyn, polyethylene, ethylene copolymers,
ethyl-propylene-non-conjugated diene terpolymer, etc.
(6) Acrylic resins and blends of these resins with poly vinyl
chloride, elastomers, etc.
(7) Thermoplastics such as the urethanes, olefinic thermoplastic
rubbers such as blends of polyolefins with
ethylene-propylene-non-conjugated diene terpolymer, block
copolymers of styrene and butadiene, isoprene or ethylene-butylene
rubber, or copoly (ether-amide), such as PEBAX.RTM. sold by ELF
Atochem.
(8) Polyphenylene oxide resins, or blends of polyphenylene oxide
with high impact polystyrene as sold under the trademark NORYL.RTM.
by General Electric Company, Pittsfield, Mass.
(9) Thermoplastic polyesters, such as polyethylene terephthalate,
polybutylene terephthalate, polyethylene terephthalate/glycol
modified and elastomers sold under the trademarks HYTREL.RTM. by
E.I. DuPont De Nemours & Company of Wilmington, Del. and
LOMOD.RTM. by General Electric Company, Pittsfield, Mass.
(10) Blends and alloys, including polycarbonate with acrylonitrile
butadiene styrene, polybutylene terephthalate, polyethylene
terephthalate, styrene maleic anhydride, polyethylene, elastomers,
etc. and polyvinyl chloride with acrylonitrile butadiene styrene or
ethylene vinyl acetate or other elastomers. Blends of thermoplastic
rubbers with polyethylene, propylene, polyacetal, nylon,
polyesters, cellulose esters, etc.
Preferably, the cover 4 is comprised of polymers such as ethylene,
propylene, butene-1 or hexane-1 based homopolymers and copolymers
including functional monomers such as acrylic and methacrylic acid
and fully or partially neutralized ionomer resins and their blends,
methyl acrylate, methyl methacrylate homopolymers and copolymers,
imidized, amino group containing polymers, polycarbonate,
reinforced polyamides, polyphenylene oxide, high impact
polystyrene, polyether ketone, polysulfone, poly (phenylene
sulfide), acrylonitrile-butadiene, acrylic-styrene-acrylonitrile,
poly (ethylene terephthalate), poly (butylene terephthalate), poly
(ethylene vinyl alcohol), poly (tetrafluoroethylene) and their
copolymers including functional comonomers and blends thereof.
Still further, the cover 4 is preferably comprised of a polyether
or polyester thermoplastic urethane, a thermoset polyurethane, a
low modulus ionomer such as acid-containing ethylene copolymer
ionomers, including E/X/Y terpolymers where E is ethylene, X is an
acrylate or methacrylate-based softening comonomer present in 0-50
weight percent and Y is acrylic or methacrylic acid present in 5-35
weight percent. More preferably, in a low spin rate embodiment
designed for maximum distance, the acrylic or methacrylic acid is
present in 15-35 weight percent, making the ionomer a high modulus
ionomer. In a high spin embodiment, the acid is present in 10-15
weight percent or a blend of a low modulus ionomer with a standard
ionomer is used.
The outer core 9 is preferably made of thermoset rubber base
materials, including those conventionally employed in golf ball
cores. The conventional materials for such cores include
compositions having a base rubber, a crosslinking agent, a filler
and a co-crosslinking agent. The base rubber is typically a
synthetic rubber like 1,4-polybutadiene having a cis-structure of
at least 40%. Natural rubber, polyisoprene rubber and/or
styrene-butadiene rubber may optionally be added to the
1,4-polybutadiene. The initiator included in the core composition
can be any polymerization initiator which decomposes during the
cure cycle. The crosslinking agent includes a metal salt of an
unsaturated fatty acid such as sodium, zinc, lithium or magnesium
salt or an unsaturated fatty acid having 3 to 8 carbon atoms such
as acrylic or methacrylic acid. The filler typically includes
materials such as zinc oxide, barium sulfate, silica, calcium
carbonate, zinc carbonate, regrind and the like.
Alternatively, the outer core 9 may be comprised of thermoplastic
elastomers such as a thermoplastic polyesterester, thermoplastic
polyetherester, dynamically vulcanized thermoplastic elastomers,
functionalized styrene-butadiene elastomers, thermoplastic
urethanes or metallocene polymers or blends thereof.
The present invention is not limited to a particular outer core 9
material, and the materials are well known to those of ordinary
skill in the art. The present invention is generally directed to
the use of a standard thermoset material, but those of ordinary
skill will easily know how to convert the process for using
thermoplastic materials.
The outer core 9 preferably has an outside diameter in the range of
80 to 98% of the finished ball diameter and an inner diameter in
the range of 30 to 90% of the finished ball diameter. Preferably,
the outer core 9 has an inner diameter of approximately 0.8 to 1.5
inches and, more preferably, the inner diameter is approximately
1.0 to 1.5 inches. Yet further still, the outer core 16 has an
outside diameter in the range of 1.3 to 1.7 inches and, more
preferably, approximately 1.5 to 1.6 inches.
A golf ball incorporating these measurements can be designed with
the various attributes discussed below, such as specific gravity,
resiliency and hardness, to provide the desired playing
characteristics, such as spin rate and initial velocity.
Referring to FIG. 3, the method for making golf balls of the
present invention uses a molding apparatus 10. The molding
apparatus 10 includes a frame assembly 12, a guide assembly 14, a
slide assembly 16, a lower elevator assembly 18, an upper elevator
assembly 20, a rotating assembly 22, a light source 24, sensors 26,
a plurality of lock assemblies 28, controls (not shown), and a mold
press 30. Preferably a combination of pneumatic, electrical, and
computerized systems are used to control the operation of the
apparatus, however any conventional manufacturing controls known to
those skilled in the art can be used to control the apparatus
operation. Referring to FIG. 4, the molding apparatus 10 further
includes a bottom mold plate 32, a top mold plate 34, and a center
mold plate 36.
Referring to FIG. 5, the frame assembly 12 includes two frame
sections 38 and 40 joined to form a substantially L-shaped frame.
Reference is made to a three-dimensional Cartesian Coordinate
system including perpendicular x, y, and z axes or directions. The
frame sections 38 and 40 include elongated members that form
rectangular three-dimensional boxes. The first frame section or
slide frame 38 is elongated more in the y-direction than in the x-
and z-directions, so the slide frame 38 extends substantially
horizontally and longitudinally. The second frame section or
elevator frame 40 is elongated more in the z-direction than in the
x- and y-directions, so that the elevator frame extends
substantially vertically.
Referring to FIG. 5, the slide frame 38 has a first end 38a, a
spaced second end 38b, and further includes a pair of lower
longitudinal members 42, a pair of upper longitudinal members 44,
four pairs of vertical members 46, four upper transverse members
48, four lower transverse members 50, and a pair of inclined
members 52.
The pair of upper longitudinal members 44 are longer than the pair
of lower longitudinal members 42 such that the upper pair 44 extend
beyond the lower pair 42 at the second end 38b of the slide frame
38.
The pairs of vertical members 46 join the lower and upper
longitudinally extending members 42 and 44. Each pair of vertical
members 46 are spaced longitudinally from the adjacent pair.
The upper transverse members 48 extend between the upper
longitudinal members 44. The lower transverse members 50 extend
between the lower longitudinal members 42. Each inclined member 52
extends from the center of the associated vertical member 46 at the
second end 38b to the second end 38b of the upper longitudinal
member 44.
The upper longitudinal members 44 and the three upper transverse
members 48 closest to the second end 38b include spaced frame pads
54 of various sizes attached to the upper surfaces thereof. The
various sized pads define either one or two holes, which extend
through the entire pad to enable mounting of the guide assembly 14
(as shown in FIG. 3) on the upper surface of the pads using
conventional fasteners.
The slide frame 38 further includes two reflector assemblies 56
attached thereto at the first end 38a. Each reflector assembly 56
includes an upper mount plate 58, a lower mount plate 60, a lower
mount member 62, a vertical member 64, an upper mount member 66, a
tubular member 68, and a mirror 70.
The upper mount plate 58 is coupled to the upper corner of the
slide frame 38 above the vertical member 46 at the first end 38a.
The lower mount plate 60 is coupled to the center of the vertical
member 46 at the first end 38a. The lower mount member 62 is
coupled to and horizontally extends from the lower mount plate 60.
The vertical member 64 extends vertically from the upper surface of
the upper mount plate 58. The upper mount member 66 is coupled to
and horizontally extends from the vertical member 64. The lower and
upper mount members 62 and 66 are parallel to one another and
extend away from the first end 38a of the slide frame 38. The
tubular member 68 extends between the lower and upper mount members
62 and 66. The lower and upper mount plates 58 and 60, mount
members 62 and 66, the vertical member 64 and the tubular member 68
are joined together using conventional fasteners. The mirror 70 is
rotatably mounted to the tubular member 68.
Referring again to FIG. 5, the elevator frame 40 is aligned with
the slide frame 38, and includes a lower rectangular frame 72, a
spaced upper rectangular frame 74, a plurality of vertical members
76, a rotating assembly mount frame 80, and a light source/receiver
unit 82 (as shown in FIG. 3).
Referring to FIG. 5, the lower rectangular frame 72 is coupled to
the lower longitudinal members 42 of the slide frame 38. The
elevator frame 40 supports the slide frame 38 that extends
therethrough. The vertical members 76 join the lower and upper
frames 72 and 74 of the elevator frame 40. One vertical member 76
connects each comer of the lower frame 72 to each comer of the
upper frame 74.
At least one of the vertical members 76 includes a bracket 84 that
is attached thereto. The bracket 84 supports a hydraulic cushion 86
(as shown in FIG. 10) that is attached thereto.
The upper rectangular frame 74 further includes two pairs of upper
elevator support members 88 and 90. The support members 88 extend
longitudinally and are spaced apart. The first pair of upper
elevator support members 88 is connected to the upper rectangular
frame 74 by brackets 92. The support members 90 extend transversely
between the first pair of upper elevator support members 88.
The rotating assembly mount frame 80 includes two pairs of
longitudinally extending mount members 94. The members 94 extend
between the vertical support members 76, respectively. The mount
members 94 are vertically positioned between the slide frame 38 and
the upper frame 74.
Referring to FIG. 3, a pair of sensor array supports 96 extend
longitudinally between the vertical members 76. The supports 96 are
located on the upper end of the elevator frame 40 between the
rotating assembly mount frame 80 and the upper frame 74. Each
sensor array support 96 is secured to the elevator frame 40 by
brackets 98, which are mounted to the vertical members 76.
Referring to FIG. 3, one light source/receiver unit 100 is attached
to each of the vertical support members 76 closest to the slide
frame first end 38a. Each unit 100 produces a light beam that
travels the longitudinal length of the slide frame 38 toward the
mirror 70. Each unit 100 is in electronic communication with the
controls. The mirror 70 reflects the beam of light back toward the
unit 100.
When the unit 100 receives the light, a circuit is completed. If
the light path from the mirror 70 to the unit 100 is obstructed,
the circuit will not be completed. An incomplete circuit causes a
signal to be sent to the controls from the unit 100. The signal
prevents movement of various parts of the apparatus along the slide
frame 38.
Referring to FIG. 6, the guide assembly 14 includes three pairs of
guide blocks 102-106 mounted to the upper surface of the upper
longitudinal members 44 of the slide frame 38 on the pads. The
first pair of guide blocks 102 closest to the second end 38b of the
slide frame 38 defines a working station W. The second pair of
guide blocks 104 defines an intermediate loading station IL. The
third pair of guide blocks 106 defines an end loading station
EL.
Each guide block 102-106 is a rectangular track with two sets of
cam-follower bearings 108 and 110. In the first set, the
cam-follower bearings 108 are rotatably coupled to the upper
surface of each guide block. Cam-follower bearings 108 rotate about
an axis z' that is parallel to the z-axis. In the second set, the
cam-follower bearings 110 are rotatably coupled to the inner, side
surface of each guide block. Cam-follower bearings 110 rotate about
an axis x' that is parallel to the x-axis. During operation, the
second set of cam-follower bearings 110 support the mold plates
thereon, and the first set of cam-follower bearings 108 prevent the
mold plates from moving in the transverse, or x-direction.
The first pair of guide blocks 102 further includes two sets of
working station lock assemblies 28W and 28W' coupled thereto that
secure various mold plates in the working station W. The lock
assemblies 28W and 28W' are coupled to the first pair of guide
blocks 102 so that they extend transversely therefrom. The first
set of working station lock assemblies 28W is spaced vertically
from the second set of working station lock assemblies 28W' to
allow two mold plates to be secured simultaneously at the working
station W. Each set of assemblies 28W and 28W' has a forward pair
of assemblies and a rearward pair of assemblies, where one lock
assembly in the pair is coupled to the opposing guide block.
The second and third pair of guide blocks 104 and 106 each have a
pair of intermediate and end loading lock assemblies 28IL and 28EL,
which are vertically coupled to extensions on the guide blocks. The
lock assemblies 28IL and 28EL secure various plates thereabove in
the intermediate or end loading station, respectively.
Referring to FIGS. 5-7, the slide assembly 16 transports the mold
plates longitudinally along the slide frame 38 between the various
stations W, IL and EL. The slide assembly 16 includes a base
assembly 112, a sliding member 114, and a plurality of slide lock
assemblies 28S and 28S'.
Referring to FIG. 7, the base assembly 112 includes two spaced
support feet 116, a floor member 118, and a rectangular side wall
member 120. When the slide assembly 16 is assembled to the slide
frame 38, the support feet 116 are connected to the central, upper
transverse members 48 (as shown in FIG. 5). The floor member 118
extends horizontally between the support feet 116 and is connected
thereto. The rectangular side wall member 120 is coupled to the
floor member 118 and extends vertically therefrom. The side wall
member 120 forms a chamber 122 that receives a motorized linear
slide 124. The linear slide 124 causes the sliding member 114 to
move longitudinally. One recommended linear slide is commercially
available from Thomson Industries Inc. located in Fort Washington,
N.Y. and called AccuSlide. However, any conventional motorized
slide known to those skilled in the art can be used. Other types of
components can also be used to move plates longitudinally instead
of the linear slide, such as a belt drive.
The linear slide 124 has a ball screw 126 operatively connected to
a servo motor 128. The servo motor 128 is connected to a first end
of the side wall member 120 for driving the ball screw 126. A ball
bushing bearing 130 is operatively connected to and travels along
the ball screw 126 and is coupled to the sliding member 114.
The sliding member 114 is H-shaped and includes two spaced mounting
plates 132 joined by a plate 134. The slide lock assemblies 28S and
28S' are coupled to the ends of the mounting plates 132 and
releasably couple the mold plates to the sliding member 114. The
sliding member 114 is shown in an extended position, where the
sliding member 114 is unaligned with the base assembly 112. Sensors
(not shown) are mounted on the base assembly 112 to detect the
position of the sliding member 114.
Referring to FIGS. 4 and 8, the lower elevator assembly 18 includes
a lower plate 136, an actuation assembly 138, and a movable, upper
plate 140. The lower plate 136 is connected to the slide frame 38
within the elevator frame 40. Each of the lower and upper plates
136 and 140 define first holes (not shown) at the comers for
receiving guide rods 142. Each of the plates also define a second
hole (not shown) at the center of each plate for receiving a
central shaft 144.
The upper surface of the lower plate 136 further includes four ball
bushing blocks 146. The blocks 146 are at the comers for receiving
the rods 142. Each ball bushing block 146 has a bushing 150 secured
thereto for receiving each guide rod 142 and allowing smooth
vertical movement of the guide rods 142 through the block 146 and
lower plate 136. When each guide rod 142 is disposed through the
first holes and bushing blocks, the first end 142a of each guide
rod 142 is below the lower plate 136 and the second end of each
guide rod 142 receives a top cap 152 for fixedly connecting the
guide rod 142 to the upper plate 140.
One of the ball bushing blocks 146 includes a home sensor 154
mounted thereto to indicate when the upper plate 140 is in a lower
position. An upper limit sensor (not shown) is mounted in the
elevator frame 40 (as shown in FIG. 4) at the rotate or central
position to indicate the upper limit of the top plate 140 of the
lower elevator assembly 18. The top plate 140 moves between a
lowest position beneath the level of the guide blocks 102 (as shown
in FIG. 6) and the rotate position.
The actuation assembly 138 for moving the upper plate 140
vertically includes a servo motor 154 and a jack screw 156. The
servo motor 154 is connected to the lower plate 136 and operatively
connected to the jack screw 156. The central shaft 144 has a first
end 144a beneath the lower plate 136 and a second end above the
upper plate 140. A shaft coupling 158 operatively connects the jack
screw 156 to the central shaft 146. A screw cap 160 is connected to
the second end of the central shaft 144 to fixedly couple the
central shaft 144 to the upper plate 140.
The upper plate 140 defines a cutout 162 and includes a plurality
of lift elements 164. As shown in FIG. 3, once the lower elevator
18 is installed, cutout 162 is aligned with the slide assembly 16
to allow the upper plate 140 to move without the slide assembly 16
interfering with the movement of the upper plate.
Referring again to FIG. 8, the lift elements 164 are disposed at
each comer on the upper surface of the upper plate 140. The lift
elements 164 engage the mold plates, upon vertical movement of the
upper plate 140 to separate the plates from one another.
Referring to FIG. 8, each lift element 164 includes a block 166
having an upper surface 168, and a lift pin 170 extending
vertically therefrom. Each lift pin 170 includes a cylindrical base
portion 172 and a cylindrical upper portion 174. The diameter of
the base portion 172 is larger than the diameter of the upper
portion 174. The base portion 172 and the upper portion 174 are
separated by a shoulder 176. Each pin further includes a free end
178.
Referring to FIG. 9, the upper elevator assembly 20 includes a
movable lower plate 180, an actuation assembly 182, and an upper
plate 184. The upper plate 184 is connected to the support members
88 and 90 (as shown in FIG. 5) within the elevator frame 40.
Each of the lower and upper plates 180 and 184 define first holes
(not shown) at the comers for receiving guide rods 186. Each of the
plates also define a second hole (not shown) at the center of each
plate for receiving a central shaft 188. The upper surface of the
upper plate 184 further includes four ball bushing blocks 190 at
the comers for receiving the rods 186. Each ball bushing block 190
has a bushing 192 secured therein for receiving each guide rod 186
and allowing smooth vertical movement of the guide rods 186 through
the block 190 and lower plate 180.
When the guide rod 186 is disposed through the first holes and the
bushing blocks, the first end 186a of each guide rod 186 is above
the upper plate 184. The second end of each guide rod 186 receives
a cap (not shown) for fixedly connecting the guide rod 186 to the
lower plate 180. One of the ball bushing blocks 190 includes a home
sensor (not shown) mounted thereto to indicate when the lower plate
is in an elevated or home position. A lower limit sensor (not
shown) is mounted in the elevator frame 40 (as shown in FIG. 5) at
the rotating position to indicate the lower limit of the lower
plate of the upper elevator assembly.
The upper surface of the lower plate 180 includes braces 194 with
an X-shape for adding rigidity to the lower plate 180. The lower
plate 180 further includes two spaced, parallel, end walls 196
connected thereto, which extend vertically below the lower surface
of the lower plate 180. Each end wall 196 has a pair of upper
elevator lock assemblies 28UE attached thereto to releasably secure
the center mold plate 34 (as shown in FIG. 4) to the upper elevator
20.
The upper surface of the upper plate 184 includes braces 198 with
an X-shape for adding rigidity to the upper plate. The upper
surface also has the actuation assembly 182 disposed thereon. The
actuation assembly 182 includes a servo motor 200 and a jack screw
202 for moving the lower plate 180 vertically. The servo motor 200
is connected to the upper plate 184 and operatively connected to
the jack screw 202. The central shaft 188 has a first end 188a
above the upper plate 184 and a second end (not shown). A shaft
coupling 204 connects the jack screw 202 to the central shaft 188.
A bracket 206 is connected to the second end of the central shaft
188 to connect the central shaft 188 to the lower plate 180.
Referring now to FIGS. 10 and 10A, the rotating assembly 22 is
mounted to the rotating mount frame 80. The rotating assembly 22
includes an actuator assembly 208, a pair of rotating subassemblies
210, and a rotating frame 212. The rotating assembly 22 is located
within the elevator frame 40 so that the rotating frame 212 can
rotate within the elevator frame 180.degree. between an upright and
an inverted position. To that end, the elevated position of the
center mold plate, as discussed below, is spaced from the rotating
position more than half the width of the rotating frame to allow
rotation of the frame.
The actuator assembly 208 is connected to a mount plate 214 that is
coupled to the outside of the first pair of longitudinally
extending mount members 94. The actuator assembly 208 has a
cylindrical shaft 216 that extends through the mount plate 214. The
actuator assembly 208 is a conventional air/oil tandem rotary
actuator available from PHD, Inc. However, other components that
impart rotary motion can be used. The shaft 216 is coupled to a
first pivot shaft 218 by a bore coupling 220. When the shaft 216
rotates, the first pivot shaft 218 also rotates. The rotation is
about a rotate axis RA. The pair of rotating subassemblies 210 are
mounted to the inside of the longitudinally extending mount members
94 on either side of the elevator frame. Each subassembly 210
includes a mount frame 222, a horizontal adjustment plate 224, a
vertical adjustment plate 226, a bearing 228, and a second pivot
shaft 230.
The mount frame 222 is coupled to the inside of one of the mount
members 94. As best shown in FIG. 5, the mount frame defines a
central bore 232 for receiving the associated shaft 218 or 230. The
mount frame 222 also includes an outwardly extending shelf 234 for
supporting the other components of the rotate assembly.
Referring to FIG. 10A, the horizontal adjustment plate 224 defines
a central hole 236 and is mounted adjacent to the mount frame 222.
The horizontal adjustment plate 224 is rectangular and also defines
four horizontal slots (not shown) to accommodate screws and allow
for horizontal adjustment of the pivot assemblies. The central hole
236 has a sufficiently large diameter to permit the second pivot
shaft 230 with a smaller diameter to enter therein.
The vertical adjustment plate 226 defines a central hole 238 and is
mounted adjacent to the horizontal adjustment plate 224. The
vertical adjustment plate 226 is rectangular and defines four
vertical slots (not shown) to accommodate screws and allow for
vertical adjustment of the pivot assemblies. The central hole 238
has a sufficiently large diameter to permit the second pivot shaft
230 to enter therein and to receive the bearing 228.
The bearing 228 has a central hole 240 for receiving and supporting
the first and second pivot shafts, respectively, and allowing
rotation of the shafts. The combination of the horizontal and
vertical adjustment plates 224 and 226 permits the adjustment of
the bearing 228 to concentrically align with the first and second
pivot shafts 218 and 230 during installation of the rotating frame
212. The pivot shaft 218 and 230 are coupled to opposite sides of
the rotating frame 212 (as best shown in FIG. 11).
Referring to FIG. 8, the rotating frame 212 includes a pair of
longitudinally extending side members 242a and 242b and a pair of
transversely extending end members 244 fastened together to form a
substantially square frame. The side members 242a and 242b include
two sets of frame locking assemblies 28F and 28F' secured thereto.
The first set of locking assemblies 28F is vertically spaced from
the second set of locking assemblies 28F' so that the rotating
frame 212 can support two mold plates. The first set of locking
assemblies 28F has two spaced assemblies at either end of the side
members 242a, and two spaced assemblies at either end of the side
members 242b. The second set of locking assemblies 28F has two
spaced assemblies at either end of the side members 242a, and two
spaced assemblies at either end of the side members 242b.
As shown in FIGS. 10 and 11, one end of one of the side members
242a includes a cushion block 246 and a sensor block 248. The
cushion and sensor blocks 246 and 248 are attached to opposite
sides of the side member 242a. The cushion block 246 is positioned
so that when the rotating frame is horizontal, the cushion block
246 contacts the hydraulic cushion 86 to prevent excess rotation of
the rotating frame 212. The sensor block 248 senses when the
cushion block 246 contacts the hydraulic cushion 86 to send a
signal to the controls to stop rotation of the rotating frame
212.
Referring to FIG. 10, the end members 244 are horseshoe-shaped, and
each has comer guide blocks 250 secured thereto. The comer guide
blocks 250 align the rotating frame 212 with the lower elevator
assembly 18 (as shown in FIG. 3) during operation.
Referring to FIG. 3, light source 24 and sensors 26 are mounted on
each sensor array support 96. The light source 24 produces a light
beam. The sensors 26 receive the light beam. If the sensors 26 do
not receive the light beam, a circuit is not completed and a signal
is sent to the controls. The purpose of the light source and
sensors is to determine if any material is on the center mold plate
34 (as shown in FIG. 4), and discussed below.
Referring to FIGS. 6,7,9,11, the working station lock assemblies
28W and 28W', the loading station lock assemblies, 28IL and 28EL,
the slide lock assemblies 28S and 28S', the upper elevator lock
assemblies 28UE, and the frame lock assemblies 28F and 28F' will
now be discussed. Referring to FIG. 12, each lock assembly
mentioned above includes an air cylinder assembly 252, a cylinder
nose 254, a connector 256, a floating coupling 258, a lock body
260, a pullout dowel 262, and a bronze bushing 264.
The air cylinder assembly 252 includes a bracket housing 266, an
air cylinder 268, and an air cylinder valve (not shown) for
activating the air cylinder 268. The air bracket housing 266
slidably receives the air cylinder 268, and the air cylinder 268
extends therefrom.
The cylinder nose 254 is connected to the free end of the air
cylinder 268. The cylinder nose 254 has a large diameter portion
254a and a small diameter portion 254b. The large diameter portion
254a of the cylinder nose is disposed within the notch 270 defined
in the floating coupling 258 to secure the nose 254 to the coupling
258.
The lock body 260 is coupled to the air cylinder assembly 252 by
fasteners 272 and defines a central slot 274. The bronze bushing
264 is secured to the opposite side of the lock body from the slot
274. The pullout dowel 262 is slidably connected to the lock body
260 by the bushing 264. The floating coupling 258 is, in turn,
operatively connected to the pullout dowel 262 by the connector
256. The slot 274 of the lock body 260 houses the connector 256,
the cylinder nose 254, and floating coupling 258.
During operation of the lock assemblies 28, the air cylinder 268
extends or retracts by actuation of the air cylinder valve.
Consequently, movement of the cylinder 268 also causes the pullout
dowel 262 to extend or retract so that the pullout dowel 262
engages and releases the various mold plates.
Referring to FIG. 13, the mold press 30 is a hydraulic press
commercially available from Brodeur Machine Company of New Bedford,
Mass. under the name "slab-sided ram" hydraulic press. However, any
mold press that is capable of producing the needed heat and
pressure can be used. The mold press 30 has a base 276, a press ram
278, and a mold support assembly 280.
The base 276 includes two side slabs (one slab 282 being shown)
that extend vertically to a top block 284. The press ram 278 is
located on the base 276 and moves a platen 279 to produce the
pressure during molding. The press ram also supports various other
moving platens, a steam platen, heating/cooling platens and
insulation, as known by these of ordinary skill in the art.
The mold support assembly 280 includes two support brackets 286
connected to the mold frame (not shown), pairs of support rods 288
and 290, and a movable frame 292. Each bracket 286 has the pair of
first support rods 288 and a pair of second support rods 290
attached thereto. The first support rods 288 support an upper press
plate 294. The second support rods 290 support the frame 292
including a pair of spaced guide blocks 296. The guide blocks 296
have cam-follower bearings 298 and 300 that are similar to those
used with the guide blocks of the guide assembly 14 (as shown on
FIG. 6).
When the press ram 278 moves vertically, the platen 282 and frame
292 move vertically. The second support rods 290 guide the movement
of the frame 292. The upper press plate 294 horizontally spans the
mold press 30 above the frame 292. A lower press plate 302
horizontally spans the mold press and is supported by the frame
292.
Referring to FIG. 4, the bottom mold plate 32, the top mold plate
34, and the center mold plate 36 will now be discussed in detail.
The bottom and top mold plates 32 and 34 include a plurality of
hemispherical mating cavities 304 that form a sphere when the
center mold plate 36 is not disposed between them. The cavities 304
are formed directly in the mold plates or comprised of replaceable
mold cavities as set forth in U.S. Pat. No. 4,508,309 issued to
Brown. The cavities 304 are formed with a radius substantially
equal to the finished core radius. Preferably, this is in the range
of about 1.50 inches to 1.65 inches as set forth above. Surrounding
each of the cavities 304 is a circumferential groove 306 (as shown
in FIGS. 14 and 15) for surplus outer core material.
The center mold plate 36 includes a plurality of protrusions 307 on
opposite sides thereof that correspond with the cavities 304 of the
top and bottom mold plates. The protrusions 307 are hemispheres,
which are substantially the same size as half of the ball inner
core 13 (as shown in FIGS. 1-2), as set forth above.
Referring to FIGS. 4 and 14, the bottom mold plate 32 further
includes two spaced, transversely extending, side walls 308a and
308b, two spaced, longitudinally extending, side walls 310a and
310b, a pair of alignment pins 312, a pair of alignment apertures
314, four lift apertures 316, four side lock apertures 318, two
forward slide apertures 320, two forward lock apertures 322, and
two arms 324.
The alignment pins 312 are located diagonally across from each
other adjacent to the two longitudinally extending side walls 310a
and 310b. The alignment apertures 314 are defined diagonally across
from each other adjacent to the two longitudinally extending side
walls 310a and 310b. The alignment pins 312 and apertures 314 are
vertical.
Referring to FIGS. 4 and 14, the lift apertures 316 extend
vertically through the plate adjacent to the two longitudinally
extending side walls 310a-b. The lift apertures 316 receive the
lift pins 170 of the lower elevator assembly 18. The diameter of
the lift apertures 316 is less than the width W of the blocks 166
and greater than the diameter of the upper portion 174 of the
pin.
Referring to FIG. 14, the side lock apertures 318 are defined in
the longitudinal side walls 310a-b of the bottom plate and extend
transversely. The side lock apertures 318 are for engagement of the
working station lock assemblies 28W (as shown in FIG. 6).
The forward slide apertures 320 are defined through the plate
adjacent to the transverse side wall 308b and extend vertically.
The forward slide apertures 320 are for engagement of slide lock
assemblies 28S (as shown in FIG. 7).
The forward lock apertures 322 are defined through the plate
adjacent sidewall 308b and extend vertically. The forward lock
apertures 322 are for engagement of the loading station lock
assemblies 28IL and 28EL (as shown in FIG. 6).
The arms 324 extend horizontally from the transverse side wall
308a, and are attached to side wall 308a with conventional
fasteners. The arms 324 define rear slide apertures 326 vertically
therethrough at the free ends. The arms 324 are spaced apart so
that the rear slide 6 apertures 326 can be engaged by the slide
lock assemblies 28S (as shown in FIG. 7).
Referring to FIGS. 4 and 15, the top mold plate 34 further includes
two spaced transversely extending side walls 328a and 328b, two
spaced longitudinally extending side walls 330a and 330b, a pair of
alignment pins 332, a pair of alignment apertures 334, eight lift
notches 336, two sets of side lock apertures 338 and 340, two
forward slide apertures 342, two rear slide apertures 344, and two
forward lock apertures 346.
The alignment pins 332 are located diagonally across from each
other and adjacent to the two longitudinally extending side walls
330a-b. The alignment apertures 334 are defined diagonally across
from each other adjacent to the two longitudinally extending side
walls 330a-b. The alignment pins 332 and apertures 334 are
vertical. Referring to FIGS. 14 and 15, when the top mold plate 34
is inverted over the bottom mold plate 32, the alignment pins 332
on the top mold plate insert into the alignment apertures 314 of
the bottom mold plate 32 and the alignment pins 312 of the bottom
mold plate 32 insert into the alignment apertures 334 of the top
mold plate 34 to position the mold plates relative to each
other.
One set of four lift notches 336, as shown, extend vertically,
partially through the plate from the upper surface of the plate.
These notches 366 are adjacent to the two longitudinally extending
side walls 330a-b. The other set of four lift notches (not shown)
are disposed on the bottom surface of the plate. The lift notches
336 receive the lift pins 170 (shown in FIG. 4) of the lower
elevator assembly 18. The lift notches 336 have a diameter greater
than the diameter of the upper portion 74 of the lift pin 170 so
that the lift pins are received therein.
Referring to FIG. 15, outer and inner sets of side lock apertures
338 and 340 are defined in the longitudinal side walls 330a-b of
the top plate and extend transversely. The side lock apertures 338
and 340 are for engagement of the working station lock assemblies
28W (as shown in FIG. 6) and the frame lock assemblies 28F (as
shown in FIG. 7) that are transversely oriented.
The forward slide apertures 342 are defined through the plate
adjacent to the transverse side wall 328b and extend vertically.
The rear slide apertures 344 are defined through the plate adjacent
to the transverse side wall 328a and extend vertically. The forward
and rear slide apertures 342 and 344 are for engagement of slide
lock assemblies 28S (as shown in FIG. 7).
The forward lock apertures 346 are defined vertically through the
plate adjacent to the transverse side wall 328b. The forward lock
apertures 346 are for engagement of the intermediate loading
station lock assemblies 28IL (as shown in FIG. 6). Referring to
FIG. 16, the center mold plate 36 further includes two spaced,
transversely extending, side walls 348a and 348b, two spaced,
longitudinally extending, side walls 350a and 350b, a set of four
alignment apertures 352, four lift apertures 354, and two sets of
side lock apertures 356 and 358.
Referring to FIGS. 14 and 16, the alignment apertures 352 are
located in rectangular orientation spaced from each other adjacent
to the two longitudinally extending side walls 350a-b. The
alignment apertures 352 are vertical. When the center plate 36 is
disposed between the top and bottom plates 34 and 32, the alignment
apertures 352 receive the respective alignment pins 312 and 332 of
the top and bottom plates.
Referring again to FIGS. 14 and 16, the lift apertures 354 extend
vertically through the plate 36 adjacent to the two longitudinally
extending side walls 350a-b. The lift apertures 354 receive the
lift pins 170 of the lower elevator assembly 18. The diameter of
the lift apertures 354 is less than the diameter of the base
portion 172 of the lift pin 170 so that the center plate 36 will
rest on the shoulder 176.
One set of side lock apertures 356 are defined in the longitudinal
side walls 350a-b of the center plate and extend transversely. The
other set of side lock apertures 358 are defined in the transverse
side walls 348a-b of the center plate and extend longitudinally.
The side lock apertures 356 are for engagement of the frame lock
assemblies 28F (as shown in FIG. 11). The side lock apertures 358
are for engagement of the upper elevator lock assemblies 28UE (as
shown in FIG. 9).
Operation of the molding apparatus will now be discussed. Referring
to FIG. 17 (Step 1) and FIG. 3, initially the bottom mold plate 32
is located in the end loading station EL on the slide frame 38, the
top mold plate 34 is located in the intermediate loading station IL
on the slide frame 38, and the center mold plate 36 is located in
the working station W at an elevated position in the elevator frame
40.
The bottom mold plate 32 is held in the end loading station EL by
the lock assemblies 28EL (shown in FIG. 6) engaging the forward
lock apertures 322 (shown in FIG. 14). The top mold plate 34 is
held in the intermediate loading station IL by the lock assemblies
28IL (shown in FIG. 6) engaging the forward lock apertures 346
(shown in FIG. 15). The center mold plate 36 is held in the working
station W by the lock assemblies 28UE (shown in FIG. 9) engaging
side lock apertures 358. Referring to FIGS. 9 and 17 (Step 1), the
lower plate 180 is position in the elevated position and holds the
center mold plate 36 in the elevated position. In these positions,
outer core material (not shown), such as polybutadiene, is placed
in the cavities 304 (as shown in FIG. 4) of the bottom and top mold
plates. The material is in the form of preps or preforms. The
rotating frame 212 is upright.
Referring to FIG. 7, the front slide lock assemblies 28S engage the
rear slide apertures 344 (as shown in FIG. 15) of the top mold
plate 34 and the forward lock apertures 320 (as shown in FIG. 14)
of the bottom mold plate 32. The sliding assembly 114 is moved
toward the elevator frame 40. As shown in FIG. 17, in Step 2, the
top and bottom plates 34 and 32 are moved at the same time. The top
plate 34 comes to rest in the working station W and the bottom
plate 32 comes to rest at the intermediate loading station IL.
As shown in FIGS. 8, 11, and 15, the lift pins 170 of the lower
elevator 18 engage the lower surface lift notches 336 of the top
mold plate 34 and the motor 154 via the jack screw 156, rods 142
and shaft 144 raises the upper plate 140 of the lower elevator 18.
The upper plate 140 is raised (as seen in FIG. 17, Step 3) from the
lower position to the rotating position where it is aligned with
the lower set of frame lock assemblies 28F of the rotating frame
212. Once the top mold plate 34 is at the rotating frame 212, the
frame locking assemblies 28F engage the set of inner side lock
apertures 340 to secure the top mold plate 34 to the rotating frame
212 at the rotating position. The upper plate 140 of the lower
elevator 18 returns to the lowest position beneath the level of the
slide assembly. The slide assembly 16 (as shown in FIG. 7) moves so
that the forward slide lock assemblies 28S are aligned with the
forward slide apertures 320 (as shown in FIG. 14) of the bottom
mold plate 32.
At the same time in Step 3, the lower plate 180 (as shown in FIG.
9) of the upper elevator 20 moves the center mold plate 34 to the
rotating position. Once the center mold plate 34 is aligned with
the rotating frame 212, the upper frame locking assemblies 28F'
engage the lock apertures 356 (as shown in FIG. 16) of the center
mold plate 36 and the locking assemblies 28UE on the upper elevator
disengage the plate. Thereafter, the upper elevator 20 moves the
lower plate 180 back to the elevated position.
As shown in FIG. 17, (Step 4) the rotating frame 212 rotates
180.degree. and comes to rest inverted. The center and top mold
plates 36 and 34 are rotated together. After this rotation the
center plate 36 is beneath the top plate 34 so that the preps in
the top mold plate cavities are secured therein. At the same time,
the slide lock assemblies 28S (as shown in FIG. 7) engage the
forward slide apertures 320 (FIG. 14) of the bottom mold plate 32
and move the plate 32 into the working station W. Then, the slide
assembly 114 (as shown in FIG. 2) moves until the forward lock
assemblies 28S are aligned with the rear lock apertures 326 of the
bottom mold plate. Thus, all three plates are vertically aligned,
and the center mold plate is between the top and bottom mold
plates.
Referring to FIG. 4, the upper plate 140 of the lower elevator 18
rises so that the lift pins 170 extend through the lift apertures
316 in bottom mold plate 32. When the lift block 166 engages the
lower surface of the bottom mold plate 32, the bottom mold plate
rises with the upper plate 140. The bottom mold plate 32 is
elevated until it is beneath the center mold plate 36 in the
rotating position. The alignment pins 312 of the bottom mold plate
engage the alignment apertures 352 of the center mold plate and the
alignment apertures 332 (as shown in FIG. 14) of top mold plate,
thereby bringing all three mold plates into alignment.
Referring to FIGS. 4 and 11, the rotating frame locking assemblies
28F and 28F' disengage the center and top mold plates 34 and 36 so
that these plates rest on the bottom mold plate 32. Thereafter, the
lower elevator upper plate 140 descends (as shown in FIG. 17, Step
5) to return the bottom mold plate 34 to the guide blocks 102 (as
shown in FIG. 6). Consequently, all three plates descend. The upper
plate 140 then descends to the lowest position.
Now, the assembly is ready for molding. The forward slide
assemblies 28S of the slide (as shown in FIG. 7) engage the rear
slide apertures 326 on the bottom mold plate 32 (FIG. 14). The
slide plate is moved toward the mold press 30 (as shown in FIG. 3)
so that the bottom mold plate and the top and center mold plates
thereon are transported onto the guide blocks 296 (as shown in FIG.
13) within the mold press 30.
Once the three mold plates are placed into the press 30, they are
heated and compressed. Preferably, the mold plates are heated to a
first temperature that makes the polybutadiene material
significantly more pliable, but is below the cure activation
temperature. Preferably, the temperature is greater than about
150.degree. F., but less that the cure activation temperature. The
most preferred temperature is between about 190.degree. F. and
220.degree. F. The mold plates are compressed to a pressure
sufficient enough to form hemispheres from the polybutadiene
material. Preferably, the mold plates are compressed using a
hydraulic preforming pressure of about 230 psi. Using for example,
a 28 inch diameter ram for the press that produces 142,000 pounds
of force on a mold with 210 cavities, the pressure per cavity is
about 675 pounds of force per cavity. However, one of ordinary
skill in the art can vary the heat and pressure as necessary. The
mold plates are then cooled with cooling water that has a
temperature between about 60.degree. F. to 100.degree. F. and
preferably the cooling water has a temperature of about 80.degree.
F. After molding is complete, the forward slide lock assemblies 28S
(as shown in FIG. 7) engage the rear slide apertures 326 of the
bottom mold plate 32 (as shown in FIG. 14) and return the plates to
the working station W.
Referring to FIG. 17 (Step 6), and FIGS. 4 and 14-16, the upper
plate 140 of the lower elevator 18 raises to engage the three mold
plates and break the mold plates apart. The working station lock
assemblies 28W and 28W', engage the bottom and center mold plate
side lock apertures 318 and 338. The lifting pins 170 insert into
the lift pin apertures 316 and 354 of the bottom and center mold
plates respectively. The tip of the lift pins 178 engage the
notches 336 of the top mold plate 34 and lift the top mold plate 34
off of the center mold plate 36.
The working station lock assemblies 28W release the center plate
and the elevator plate 140 continues upward. The lock apertures 356
of the center plate 36 receive the upper portion 174 of the lift
pin, but are too small to receive the base portion 172 of the lift
pin so that the center plate 36 rests on the shoulder 176 and is
raised above the bottom mold plate 32. The lift apertures 316 of
the bottom mold plate 32 receive the base portion 172 of each lift
pin and the plate 32 rests on the upper surface 168 of the block
166. The lock assemblies 28W' releases the bottom mold plate.
The upper plate 140 continues to rise until the top and center mold
plates are aligned with the respective frame lock assemblies 28F
and 28F' at the rotating position. The lock assemblies 28F and 28F'
engage the plates and hold the top plate 34 over the center plate
32.
Referring to FIGS. 4 and 6, the upper plate 140 of the lower
elevator 18 descends with the bottom mold plate 32 until the bottom
mold plate 32 rests on the guide blocks 102. The upper plate 140
continues to descend to the lowest position. The bottom mold plate
32 contains formed outer core hemispheres in the cavities 304.
Referring to FIGS. 7, 14 and 17 (Step 7), the slide lock assemblies
28S engage the forward slide apertures 320 of the bottom mold plate
32 and move it to the intermediate loading station IL. The lock
assemblies 28IL (as shown in FIG. 6) engage the forward lock
apertures 322 of the bottom mold plate 32 to hold it in the
intermediate station IL. Next in Step 8 (as shown in FIG. 17), the
center and top mold plates 36 and 34 are rotated together
180.degree. by the rotating frame 212 until the top mold plate 34
is between the center and bottom mold plates 32 and 36.
Referring to FIGS. 4, 9, 11, 16, and 18 (Step 9), the lower plate
180 of the upper elevator 20 descends and the lock assemblies 28UE
engage the side lock apertures 358 of the center plate 36. The lock
assemblies 28F of the rotating frame 212 disengage from the center
mold plate 36. The lower plate 180 is moved by the servo-motor 200,
jack screw 202, rods 186 and center 188 shaft so that raises the
center mold plate 36 to the elevated position again.
Before reaching the elevated position, the lower plate 180 stops so
that the tops of the protrusions 307 (as shown in FIG. 4) on the
upper surface of the center mold plate 36 are aligned with the
light source 24 and sensors 26 (as shown in FIG. 3). The light
source 24 generates a light. If the light is not received by the
sensors 26, then some elastomeric material is on at least one of
the protrusions and an incomplete circuit exists. A signal is sent
to the controls and/or operator that the quality of the shells is
not satisfactory. If the light is received by the sensors 26, then
the cup quality is satisfactory and the circuit is complete. The
lower plate 180 continues to rise until the tops of the protrusions
307 on the lower surface of the center mold plate are aligned with
the light source 24 and sensors 26. These protrusions are similarly
checked for elastomeric material. Simultaneously, the inner cores
13 (as shown in FIGS. 1 and 2) are placed in the hemispheres in the
bottom mold plate 32 in the intermediate loading position IL.
Referring to FIGS. 7 and 18 (Step 10), the rotating frame 212
rotates the top mold plate 34 at 180.degree.. The outer core
hemispheres contained in the cavities of the top mold plate remain
in the cavities due to the temperature difference between the core
material and the plate 34. Depending on the material used the
temperature of the core material can be greater than or less than
the temperature of the plate and produce the desired result. In
this embodiment, the temperature of the core material is lower than
the temperature of the plate. At the same time, the slide lock
assemblies 28S (as shown in FIG. 7) engage the bottom mold plate
forward slide apertures 320 and move the bottom mold plate into the
working station W.
Referring to FIGS. 4, 6, and 18 (Step 11), the lower elevator 18
raises the bottom mold plate 32 to the rotating frame 212, in the
same manner as previously described in Step 3. The frame locking
assemblies 28F release the top mold plate 34. The tip 178 of the
lift pins engage the notches 336 of the top mold plate. The upper
plate 140 of the lower elevator 18 lowers the bottom and top mold
plates 32 and 34 to the guide blocks 102. The lower plate then
descends to the lowest position.
Turning to FIGS. 7 and 15, the cores are ready for molding. The
forward locking assemblies of the slide 28S engage the rear slide
apertures 326 on the bottom mold plate 32. The slide 114 is moved
forward so that the bottom mold plate and the top mold plate
thereon is transported onto the guide blocks 296 (as shown in FIG.
13) within the molding press 30.
Once the two mold plates are placed into the press 30, they are
heated and compressed. This time, the bottom and top mold plates
are heated to a temperature above the cure activation temperature
of the polybutadiene hemispheres. Preferably, the mold plates are
heated to a temperature of greater than about 290.degree. F.
Preferably, the mold plates are compressed using a hydraulic
preforming pressure of about 2000 psi. Using for example, a 28 inch
diameter ram for the press that produces 615.5 tons of force on a
mold with 210 cavities, the pressure per cavity is about 6000
pounds of force per cavity. However, one of ordinary skill in the
art can vary the pressure.
After molding is complete, the forward slide lock assemblies 28S
(as shown in FIG. 7) engage the rear lock apertures 326 (as shown
in FIG. 14) of the bottom mold plate 32 and return the plates to
the working station W.
Referring to FIGS. 4 and 18 (Step 12), the upper plate 140 of the
lower elevator 18 raises and the lift pins 170 separate the top
mold plate 34 from the bottom mold plate 32 and both plates are
lifted to the rotating frame 212, as previously described. The top
mold plate 34 is retained in the rotating frame 52 in the same
manner as described before. Thereafter, the upper plate 140 of the
lower elevator descends with the bottom mold plate 34 and the
finished cores therein.
Referring to FIG. 18 (Step 13), and FIGS. 4, 7, and 14, the
rotating frame 212 with the top mold plate 34 retained there
rotates the top mold plate 34 180.degree. so that the cavities 304
in the top mold plate are facing upwardly. At the same time, the
slide lock assemblies 28S engage the forward slide apertures 320 of
the bottom mold plate and the slide assembly 114 moves the bottom
mold plate 32 to the intermediate loading station IL.
Turning to FIGS. 4,6,15 and 18 (Step 14), the upper plate 140 of
the lower elevator 18 raises and the lift pins 170 engage the
notches 336 of the top mold plate 34. The rotating frame locking
assemblies 28F then release the top mold plate. The upper plate 140
descends with the top mold plate 34 until the top mold plate is on
the guide blocks 102 in the working station W. The upper plate 140
continues to descend to the lowest position.
Referring to FIGS. 7, 14, 15, and 18 (Step 15), forward slide lock
assemblies 28S engage the rear slide apertures 344 of the top plate
34, and the rear slide lock assemblies 28S' engage the forward
slide apertures 320 of the bottom plate 32. As the slide assembly
114 moves toward the first end 38a of the slide frame 38, it moves
the top and bottom mold plates 34 and 32. When the slide assembly
comes to rest, the top mold plate 34 is in the intermediate loading
station IL and the bottom mold plate 32 is in the end loading
station EL. The locking assemblies 28IL and 28EL (as shown in FIG.
6) engage the lock apertures 346 and 322, of the top and bottom
mold plates respectively. The two-piece cores are removed from the
bottom mold plate. Covers are formed on the cores, as discussed
above. The process can be repeated to form additional cores.
While it is apparent that the illustrative embodiments of the
invention herein disclosed fulfill the objectives stated above, it
will be appreciated that numerous modifications and other
embodiments may be devised by those skilled in the art, for
example, a series of progressively larger diameter shells can be
formed and joined by the methods disclosed. This method can also be
used to form additional intermediate layers. This method can also
be used to form multilayered cover layers. This method can also be
used with a center plate that is moved horizontally from an initial
position unaligned with the top plate to a position substantially
vertically aligned with the top plate prior to rotating these
plates together. The movements of the plates can be varied to
achieve the results of the present invention. Therefore, it will be
understood that the appended claims are intended to cover all such
modifications and embodiments which come within the spirit and
scope of the present invention.
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